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Plywood mailbox

This simple plywood mailbox can be made in a matter of hours.

Ways with wood with Mark Rayner - Project 18

Difficulty level: Moderate

You will need: 18mm treated plywood cut to the following dimensions:
two 400mm x 250mm for the sides,
two 300mm x 100mm for the upper and lower back sections,
one 300 x 198mm for the back flap,
300mm x 350mm for the front, 300mm x 320mm for the top and 250mm x 264mm for the base.
40mm galvanised nails, clean lint-free cloth, hammer, paintbrush, PVA glue, sandpaper, saw, stainless steel hinges and screws, screwdriver, and turps for cleaningthe brush. Resene Woodsman Penetrating Oil Stain tinted to Resene English Walnut.

To get the look: Mark painted the background wall with Resene Lumbersider tinted to Resene Parachute.

Other ideas: For a darker look, go for Resene Woodsman Penetrating Oil Stain tinted to Resene Pitch Black.

Step 1
Step one
Cut the plywood to the dimensions as listed above and sand any rough edges with the sandpaper.
Step 2
Step two
Fix the front and base to the side panels, as shown, using 40mm nails and PVA glue.
Step 3
Step three
Fix the two back sections to the side panels, as shown, using 40mm nails and PVA glue.
Step 4
Step four
Apply one coat of Resene Woodsman to the inside of the mailbox, brushing in the direction of the grain.
Step 5
Step five
Carefully wipe off any excess Woodsman oil stain with a clean, lint-free cloth.
Step 6
Step six
Apply one coat of Resene Woodsman to the outside of the mailbox, the top and back flap. Brush in the direction of the grain and wipe off any excess with the cloth. Leave to dry for 24 hours.
Step 7
Step seven
Repeat steps three and four, and when the inside is touch dry, fix the top into position with 40mm nails and PVA glue. Apply a second coat of Resene Woodsman to the outside of the mailbox and back flap. Wipe off any excess with the cloth and leave to dry for 24 hours.
Step 8
Step eight
Fix the back flap into position with the two hinges and stainless steel screws, as shown.

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